I will take pics soon. I had it all apart on my office desk and my boss came by (also a cyclist now that I convted him) and asked what the heck I was doing.

All the guts are in the battery which explains why replacements are so much. The head is held on by 4 2.5mm screws which have a thread locker on them. To remove, you twist just slightly and pull apart. No clips or tabs hold anything together. The front element is glass, the reflector is plastic and floating (no attachment other than friction).

The LED is soldered to a small circut board with (now that I know, thanks prev posters) heat paste sandwiched between the LED and the board. There were two phillips screws in there, but I did not have the proper stuff to undo those.

From what I can see, the job of desoldering and re-soldering a new LED should be straightforward. I plan on doing it in the next month or so before it gets dark. I don't want to mess with it until I have a new light (this is going to be my backup/helmet light). I don't see a heat-sink unless the board is shaped like a doughnut and the aluminum mates to the back of the LED. Looks to me more like the LED is pasted to the board, and the board rests against the back of the housing.... but once I disect and re-do I will be sure to take more pics....

Any suggestions on who to buy from other than DX? I am new to this whole lighting thing..... I have always liked bright lights, but previously just shelled out $ rather than tinkering on my own.